Hole plug

ABSTRACT

A hole plug includes a housing having first and second ends, a peripheral flange around the housing, an adhesive layer positioned on the peripheral flange, and at least one tab extending from an edge of the peripheral flange proximate the first end. The tab is at least flush with a plane of said adhesive layer. The tab ensures that the adhesive layer does not contact a surface of a panel when the hole plug is being installed into a hole formed through the panel.

RELATED APPLICATIONS

This application relates to and claims priority benefits from U.S. Provisional Patent Application No. 60/757,373 entitled “Hole Plug,” filed Jan. 9, 2006, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to hole plugs, and more particularly, to hole plugs configured for use in automotive applications.

BACKGROUND OF THE INVENTION

Conventional hole plugs include an adhesive layer that is overmolded onto a plastic carrier. The adhesive layer is typically a layer of meltable glue deposited on a bottom face of the carrier. Hole plugs are adapted to seal openings in metal sheets, such as on or within an automobile body. In general, each hole plug sealingly engages the metal sheet in order to provide a liquid tight barrier. U.S. Pat. No. 5,513,769, entitled “Seal for Fixing by Gluing for an Opening Made in a Metal Sheet” describes a conventional seal or hole plug. For example, if the hole plug is inserted into a hole formed through a metal sheet, the adhesive layer melts when the sheet is heated. As the metal sheet cools, the adhesive layer secures the hole plug to the metal sheet.

In order to secure the hole plug into an opening, the hole plug may be installed into the opening by starting the plugs into the hole with a sliding action, or at an angle that is less than perpendicular. During this process, however, the adhesive portion of the hole plug may be damaged, depending on the particular design of the hole plug. During installation, for example, if the installer is not careful, the adhesive layer may catch on the lip of the sheet that defines the hole. As the installation process continues, the adhesive layer may peel away from the plastic carrier. Thus, the hole plug may be discarded, or installed improperly such that a proper seal is not formed.

Thus, a need exists for a hole plug that includes an adhesive layer that is less susceptible to being peeled away, or otherwise removed, during an installation process.

SUMMARY OF THE INVENTION

Certain embodiments of the present invention provide a hole plug configured to be positioned within an opening of a panel. The hole plug may include a housing having a first or closed end and a second or channel end, a flange integrally formed around a base of the housing, and an adhesive layer positioned on said flange. The adhesive layer may be configured to melt upon heating.

At least one tab extends from an edge of the flange proximate the closed end. The tab is at least flush with a plane of the adhesive layer.

At least one lip may extend from the housing toward the tab proximate the closed end. The tab and the lip cooperate to separate the adhesive layer from the panel until the hole plug is securely installed into the opening of the structure. The lip may include a curved surface configured to engage an edge of the panel, such that the edge of the panel is positioned between the tab and the lip.

A plurality of resilient spring clips may extend from the channel end of the housing.

The flange may include a plurality of passages. The passages allow the adhesive layer to be injected to the other side of the flange.

The housing may be semi-cylindrical. A cross section of the closed end may be smaller than a cross section of the channel end. A channel may be formed through the channel end. The channel may be in communication with an interior cavity of the housing.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates a top plan view of a hole plug according to an embodiment of the present invention.

FIG. 2 illustrates an isometric top view of a hole plug according to an embodiment of the present invention.

FIG. 3 illustrates a channel end view of a hole plug according to an embodiment of the present invention.

FIG. 4 illustrates a lateral view of a hole plug according to an embodiment of the present invention.

FIG. 5 illustrates a front view of a panel according to an embodiment of the present invention.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 illustrate a top plan view and an isometric top view, respectively, of a hole plug 10 according to an embodiment of the present invention. The hole plug 10 includes a main carrier body 12. The main carrier body 12 includes a planar flange 14 integrally connected with a housing 16 extending above the flange 14. The flange 14 is configured to support an adhesive layer, such as a layer of meltable glue. The housing 16 includes a closed end 18 and a channel end 20.

FIG. 3 illustrates a channel end view of the hole plug 10. Referring to FIGS. 1-3, a channel 22 is formed through the channel end 20 proximate the flange 14. The channel 22 provides a passage to an interior cavity (not shown) defined underneath the housing 16. The interior cavity may be closed or open ended. Resilient spring clips 25 are positioned on either side of the channel 22 and extend toward an end 27 of the hole plug 10. The spring clips 25 are longitudinally aligned with the hole plug 10 along axis x. The channel 22 and the interior cavity may be configured to securely retain a structure, such as a rod, post, or the like.

Referring again to FIGS. 1 and 2, the closed end 18 of the housing 16 may be rounded or otherwise curved. An upstanding tab 24 upwardly extends from a distal edge of the flange 14 proximate the closed end 18 of the housing 16. As shown in FIG. 1, the tab 24 is separated from the housing 16 by the flange 14. A lip 26 extends outwardly from a lower portion of the housing 16 toward the tab 24. While one tab 24 and one lip 26 are shown, the hole plug 10 may include more than one tab 24 and lip 26. For example, additional tabs 24 and corresponding lips 26 may be positioned around the housing 16 at various other locations.

An adhesive is deposited on the flange 14 around the housing 16. The adhesive may be a viscous fluid, such as glue, that may be deposited on the flange 14 through passages (not shown) formed through the flange 14. For example, the adhesive may be injected through the passages from the underside of the flange 14. Optionally, the adhesive may simply be deposited on top of the flange 14.

FIG. 4 illustrates a lateral view of the hole plug 10. An adhesive layer 30 is deposited over the flange 14. As shown in FIG. 2, the tab 24 may extend above the flange 14 and be flush with the top surface of the adhesive layer 30. Optionally, the tab 24 may extend above the plane of the adhesive layer 30.

FIG. 5 illustrates a front view of a panel 40. The panel 40 may be formed of sheet metal. For example, the panel 40 may be part of an automobile chassis. An opening 42 is formed through the panel 40. The opening 42 is defined by upper, lateral, and lower interior edges 44, 46, and 48, respectively, of the panel 40.

Referring to FIGS. 4 and 5, in order to install the hole plug 10 into the opening 42 of the panel 40, the housing 16 is first positioned through the opening 42. As the housing 16 is positioned through the opening 42, the tab 24 abuts against a first side of the panel 40 proximate the lower edge 48, while the lip 26 abuts against an opposite side of the panel 40 proximate the lower edge 48. The abutment of the tab 24 into the first side of the panel 40, and the abutment of the lip 26 into the opposite side of the panel 40 ensures that the adhesive layer 30 does not contact the panel 40 during the initial installation step That is, the tab 24 and the lip 26 cooperate with one another to ensure that the adhesive layer 30 does not touch the panel 40 during the initial installation step.

Once the hole plug 10 is aligned with the opening 42 such that the housing 16 passes into the hole and the tab 24 abuts against the panel 40, the end 27 of the hole plug 10 is pivoted toward the panel 40 in the direction of arc A about the pivot point formed by the tab 24 abutting the panel 40. As shown in FIG. 4, the underside 32 of the lip 26 is curved in order to facilitate pivotable movement of the hole plug 10. During this movement, the tab 24 and the lip 26 continue to cooperate to ensure that the adhesive layer 30 does not touch the panel 40.

As the hole plug 10 continues to be pivoted in the direction of arc A toward the panel 40, the spring clips 25 encounter the panel 40 proximate the upper edge 44. The hole plug 10 is continually urged in the direction of arc A until the spring clips 25 snapably engage the panel 40. As the hole plug 10 is snapably secured into the opening 42, the adhesive layer 30 contacts the panel 40, thereby providing a sealing engagement. The adhesive layer 30 makes contact with the panel 40 after the hole plug 10 is securely installed into the opening 42. Optionally, the adhesive layer 30 may make contact with the panel 40 only after the adhesive layer is melted. The tab 24 and lip 26 separate the adhesive layer 30 from the panel 40 until the hole plug 10 is in its final secured position. Thus, the adhesive layer 30 properly contacts the panel 40, without the risk of being removed during an installation process. Because the adhesive layer 30 contacts the panel 40 after the hole plug 10 is secured into the opening 42 of the panel 40, the adhesive layer 30 is not susceptible to being removed during initial or intermediate installation steps.

While FIGS. 1-4 show the hole plug 10 having an expanding semi-cylindrical shape, the hole plug 10 may be formed having various shapes and sizes. For example, the hole plug 10 may include a housing having a rectangular, semi-spherical, or various other shapes. Additionally, the hole plug 10 may not include the channel 22. Overall, the hole plug 10 may be sized and shaped to fit in various sizes openings and holes.

While various spatial terms, such as upper, lower, mid, lateral, horizontal, vertical, and the like may used to describe portions of the hole plug, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.

Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.

Various features of the invention are set forth in the following claims. 

1. A hole plug comprising: a housing having first and second ends; a peripheral flange around said housing; an adhesive layer positioned on said peripheral flange; and at least one tab extending from an edge of said peripheral flange proximate said first end, said at least one tab being at least flush with a plane of said adhesive layer.
 2. The hole plug of claim 1, further comprising at least one lip extending from said housing toward said at least one tab proximate said first end, said at least one tab and said at least one lip cooperating to separate said adhesive layer from a structure until the hole plug is securely installed into an opening of the structure.
 3. The hole plug of claim 2, wherein said at least one lip comprises a curved surface configured to engage a panel edge.
 4. The hole plug of claim 1, further comprising at least one resilient spring clip extending from said second end of said housing.
 5. The hole plug of claim 1, wherein said peripheral flange comprises a plurality of passages configured to allow said adhesive layer to be injected therethrough.
 6. The hole plug of claim 1, wherein said housing is semi-cylindrical, wherein a cross section of said first end is smaller than a cross section of said second end.
 7. The hole plug of claim 6, wherein a channel is formed through said second end, said channel being in communication with an interior cavity of said housing.
 8. A hole plug configured to be positioned within an opening of a panel, the hole plug comprising: a housing having a closed end and a channel end; a flange integrally formed around a base of said housing; an adhesive layer positioned on said flange; and a tab extending from an edge of said flange proximate said closed end, said at tab being at least flush with a plane of said adhesive layer.
 9. The hole plug of claim 8, further comprising a lip extending from said housing toward said tab proximate said closed end, said tab and said lip cooperating to separate said adhesive layer from the panel until the hole plug is securely installed into the opening of the structure.
 10. The hole plug of claim 9, wherein said lip comprises a curved surface configured to engage a panel edge, wherein the panel edge is positioned between said tab and said lip.
 11. The hole plug of claim 8, further comprising at least one resilient spring clip extending from said channel end of said housing.
 12. The hole plug of claim 8, wherein said flange comprises a plurality of passages configured to allow said adhesive layer to be injected therethrough.
 13. The hole plug of claim 8, wherein said housing is semi-cylindrical, wherein a cross section of said closed end is smaller than a cross section of said channel end.
 14. The hole plug of claim 13, wherein a channel is formed through said channel end, said channel being in communication with an interior cavity of said housing.
 15. A hole plug configured to be positioned within an opening of a panel, the hole plug comprising: a housing having a closed end and a channel end; a flange integrally formed around a base of said housing; an adhesive layer positioned on said flange; a tab extending from an edge of said flange proximate said closed end, said at tab being at least flush with a plane of said adhesive layer; a lip extending from said housing toward said tab proximate said closed end, said tab and said lip cooperating to separate said adhesive layer from the panel until the hole plug is securely installed into the opening of the structure, said lip comprising a curved surface configured to engage an edge of the panel, wherein the edge of the panel is positioned between said tab and said lip; and a plurality of resilient spring clips extending from said channel end of said housing.
 16. The hole plug of claim 15, wherein said flange comprises a plurality of passages configured to allow said adhesive layer to be injected therethrough.
 17. The hole plug of claim 15, wherein said housing is semi-cylindrical, wherein a cross section of said closed end is smaller than a cross section of said channel end.
 18. The hole plug of claim 17, wherein a channel is formed through said channel end, said channel being in communication with an interior cavity of said housing.
 19. The hole plug of claim 15, wherein said adhesive layer is configured to melt when heated. 